ArcGen Hilta SMC TELELIGHT TL-90 Manual

S.OPM.004 Aus. ISSUE 25.11.11
OPERATION & MAINTENANCE MANUAL
TELELIGHT
TL-90 LIGHTING TOWER
The information in this manual is subject to change without prior notice.
SMC Light & Power
SMC Light & Power a division of Arc-Gen Ltd.
Belchmire Lane, Gosberton, Lincs PE11 4HG UK
Tel: [phone] Fax: [phone] E-mail: [e-mail] Web: www.smclightandpower.com

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Enter the machine Serial Number here for future
reference when ordering replacement parts.
………………………………
Enter name & address of authorised distributer
if applicable.
……………………………………………….
……………………………………………….
……………………………………………….
……………………………………………….
Original Instruction v 25.11.11

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TABLE OF CONTENTS
Section Subject Page
1. WARRANTY 5
2. IDENTIFICATION OF WARNINGS & DANGER 5
2.1 Personal Protective Equipment (PPE) 5
2.2 Introduction to the machine 5
2.3 Introduction to the handbook 6
2.4 Warning 7
2.5 Safety Instructions 8
2.6 Instructions & Safety Labels 9
2.7 Controls 13
3. GENERAL 15
3.1 Using the operation & maintenance manual 15
3.2 Marking 15
3.3 EC Declaration of Conformity 17
3.4 Technical information 18
4. OPERATION 19
4.1 Inspection & preliminary operation 19
4.2 Manoeuvring 20
4.3 Maximum wind 20
4.4 Earth requirement 20
4.5 Miniature Circuit Breakers 20
4.6 Starting the engine 21
4.7 Unit positioning and mast deployment 21
4.8 Operating the lights 22
4.9 Outlet power sockets 22
4.10 Lowering of mast 22
4.11 Preparing for removal from site 23
5. TRANSPORT and STORAGE 14
5.1 Prior to transportation 14
5.2 Lifting the Telelight 14
5.3 Transport by lorry 15
5.4 Storage 15
6. MAINTENANCE 24
6.1 Service 24
6.2 Safety information 25
6.3 Routine maintenance 26
6.4 Diesel generator maintenance 27
6.5 Mast maintenance 27
7. MAST DISASSEMBLY & REASSEMB LY 27
7.1 Disassembly 28
7.2 Reassembly –Wire ropes 28
7.3 Reassembly –Wear pads 29
8. TROUBLESHOOTING 32

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1. WARRANTY
Warranty pertaining to your Telelight is explained in the Company’s separate booklet
entitled Registration & Warranty Information.
This booklet should be read in conjunction with these operator’s guidance notes.
2. IDENTIFICATION OF WARNINGS & DANGER
Failure to follow the warning instructions could result in severe injury or death to the
operator, a bystander or a person inspecting or repairing the machine.
All parts of the manual to do with the safety of the operator, or the safe operation of
the machine, are marked with the following symbols.
WARNING
CAUTION
2.1 PERSONAL PROTECTIVE EQUIPMENT
DO NOT wear loose clothing around the machine that may become caught on
projections or any moving part. Avoid wet clothing, change overalls immediately. Use
safety items –PPE e.g. hard hat, safety protection, safety goggles, gloves, etc., as
appropriate or required.
DO NOT operate the machine or any equipment attached to it while under the
influence of alcohol, medication, or other drugs, or while fatigued.
2.2 INTRODUCTION
The TL90 Telelights intended use is to provide flood lighting to a wide variety of
applications. It is a self-contained unit with it’s own diesel engine/generator power
supply. The entire unit is fully mounted onto a fast tow trailer with overrun and park
brake facility. Road lighting is fitted as standard.
WARNING
This symbol identifies a hazard existing. If proper precautions are
not taken, it is highly probable that the operator (or others) could
be killed or seriously injured.
CACAUTION
This symbol identifies a reminder of safe practices. Failure to
observe these safety practices could result in injury to the operator
(or others) and possible damage to machine
INFROMATION
This symbol identifies instructions that make it easier to use
the machine effectively & economically.
Carefully consult the manual before carrying out any operation
on the machine.

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A central lifting eye and fork pockets are incorporated for ease of loading on & off
transport.
The rotating mast has 9 sections that extend by hydraulic cylinder and via wire ropes
to a height of 9.0 metres. The mast is fitted with four Metal Halide Lamps.
Two external power sockets are provided. Four stabiliser legs are fitted for safe
operation when mast is deployed.
The entire unit is fully mounted onto a fast tow trailer with overrun and park brake
facility. Road lighting is fitted as standard.
An optional Power Tilt mechanism for remote adjustment of lamps is available.
Optional auxiliary fuel connections are available when required for extended run.
An Auto-Start option is available, this allows the machine to start and run for a pre-set
time.
Modifications & alterations to this machine are strictly forbidden, unless with prior
consent of SMC Light & Power. Modifications made without consent could affect the
safety of the machine & operator and would invalidate the warranty.
If the machine is used in a way contrary to its intended use, modified without prior
written consent or is incorrectly or recklessly and/or maintained, SMC Light & Power.
will not accept any liability whatsoever for damage or injury whether direct or
consequential.
2.3 INTRODUCTION OF THIS HANDBOOK
The contents of this handbook are intended as a guide to the operation &
maintenance of the TL-90 Telelight.
This handbook is not a training manual.
It is designed as a guide to the machines controls & working capacities and general
maintenance only. It must not be removed from the machine and should be kept clean
& in good condition. Additional copies of the of the
Handbook can be obtained from your dealer or directly from the manufacturer.
Only trained operators should use this machine.
It is recommended that personnel responsible for the operation and servicing of this
machine be fully trained in its safe operation. If you have any doubts about any
aspects of the machine’s capability or service procedures please contact your dealer
or the manufacturer.
In this handbook and on the machine there are safety notes, each note starts with a
single word or symbol, the meaning of these are explained below.
In general these notes are used to indicate that the procedures described in the
handbook must be followed to avoid serious injury or death to yourself or others.
The notes are also advise on the correct procedures for safe servicing.
These notes do not replace safety codes, insurance requirements & local laws.
Make sure the machine complies with local regulations.

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WARNING
2.4 WARNING
WARNING
The engine and generator set comprises components and fluids that, in operation, are
subject to high temperature. Caution is required to avoid burns and scalding.
The Telelight is equipped with moving parts, pulleys & belts. Be careful in the vicinity
of the machine.
.
In case of fire do not use water. Use only an appropriate fire extinguisher.
Do not operate the Telelight in poorly ventilated areas, as exhaust gasses can be
extremely dangerous/fatal.
2.5 SAFETY INSTRUCTIONS
CAUTION
For safety operation observe the following instructions:
Exhaust gases
The exhaust gases contain harmful carbon monoxide. Operate the Telelight in a
spacious, well ventilated, area.
Electric shock prevention
Avoid the wearing of wet clothing when operating machine.
Fire prevention
Avoid placing any flammable materials near the exhaust outlet during operation.
When filling the fuel tank be sure to stop the engine and take care not to spill fuel. Do
not refuel near fire, flame or sparks. Do not smoke whilst refuelling. Wipe off any spilt
fuel immediately before re-use.
Other precautions
Never allow untrained persons to operate the Telelight.
Never move the Telelight during operation.
Operate the Telelight on a level base.
During use, keep the Telelight at distance from buildings and be sure that the exhaust
gases are not conveyed into buildings or closed environments.
It is the responsibility of the operator to fully read the handbook
& understand it before operating the machine.
Voltage used in this equipment can endanger life. Before attempting
replacement of components or maintenance operations, ensure that
any power supply and the generator are switched off.

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Do not use the unit for lifting purposes or for anything other than that for which it is
designed.
2.6 INSTRUCTION & SAFTEY LABELS ON MACHINE
The drawings are provided by way of example. The operating instruction, warning &
safety labels form an integral part of the Telelight. The unit you have in your
possession may differ in minor areas, the safety of the unit and the information
provided are nevertheless guaranteed.
DIAGRAMS/ LABEL EXPLANATIONS
LA16666
Figure 1 Front Elevation

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Figure 2 Side Elevation
Figure 3 Rear Elevation + Radiator

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LA15461
Danger of entanglement and cutting. Presence of rotating
parts, pulleys, belts and fan.
LA16533
Danger of burns: Hot surfaces.
LA15459
Danger of electric discharge: consult the manual.
Danger of possible corrosive acid leaks.
L
LA15647
Figure 4 Upper Elevation
DIAGRAMS/ LABEL EXPLANATIONS
Danger Symbols

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LA 01945
Danger of burns: Possibility of pressurised hot water
expulsion.
.
LA15447
The fuels are highly flammable and can be explosive.
Fill in well ventilated area with engine off.
Do not smoke or create sparks while filling.
Immediately clean off any fuel leaks.
LA15464
Danger of electric discharge: consult the manual.
LA15992
Danger of machine starting automatically.
Obligation Symbols
Information Symbols
LA15653
LA16312
LA15603
Obligation to connect equipment to earth.
LA03022
Obligation to ensure bund is drained regularly.
LA15462
Indicates the position of the lifting hook(s) of the unit.
LA16312
Indicates the position of the forklift pockets.

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General Labels
LA16313 LA16351
LA15604 LA15584
Transport Mode
Deployed Mode 2
Deployed Mode 1
Lamp Deployment
LA15587
LA16350 (optional) LA15587 LA15933

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LA15649 LA15602
LA16996
LA16996
Operation & Maintenance Manual
Located behind rear access door
2.7 CONTROLS
Control Module

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This button switches on the engine control module and starts the
engine.
Control Module Button and LED Function
This button stops the engine and resets the module.
This button tilts the lamps upwards (optional equipment)
This button tilts the lamps downwards (optional equipment)
This button raises mast
This button lowers mast
Permanent LED illumination means engine protection working
Battery charge alternator LED –illuminates to show charge alternator
fault.
Low engine oil pressure LED –illuminates to show low oil pressure
and stops engine.
High engine coolant temperature LED –illuminates to show high
coolant temperature and stops engine.
Engine glow plug LED –illuminates to show glow plugs are active.
Start failure LED –illuminates to show engine starting fault.
Thermal fuse LED –illuminates to show short circuit.

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3. GENERAL
3.1 USING THE OPERATION & MAINTENANCE MANUAL
The scope of this document is to support the operator in safely deploying and
maintaining the Telelight.
This manual is organised in sections with the following information:
Section 1
Warranty Information.
Section 2
Section 2 contains the most important warning and safety instructions. More specific
safety information is contained in the specific sections for maintenance and operation.
Section 3
Section 3 gives general information about the Telelight. This section also includes help
in handbook interpretation includes the technical data of the Telelight and it’s main
sub-assembly components. The information included in this section may be duplicated
or integrated in the diesel engine manuals, the AC alternator manual and the control
panel wiring diagrams.
Section 4
Section 4 refers to inspection and preliminary operation. It includes useful information
on deployment, outlet sockets, earthing, manoeuvring and preparing for removal of
Telelight from site.
Section 5
Section 5 provides information on transport, storage, lifting and handling the Telelight.
Section 6
Section 6 provides information and procedures for routine, corrective maintenance
and advice on safety. The section also includes a timetable for periodic maintenance.
This section has to be read in conjunction with the engine and alternator maintenance
books that are supplied with the Telelight.
The Serial Number of the Telelight should be quoted in any communication.
3.2 MARKING
The Telelight identification plate contains all the identification data required to conform
to the provisions for CE Marking. The plate is fitted on the front right hand side of each
Telelight, an example is shown in Fig. A.

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Gosberton, Lincs, PE11 4HG
Tel: [phone] Fax: [phone]
Website: www.smclightandpower.com
E-mail: [e-mail]
MACHINE TYPE
SERIAL No.
YEAR OF MANUFACTURE
SMC Light & Power
ENGINE POWER 7.7 kW @ 1500rpm
SGNT90003
KG
1 -1050 KG
KG
TL-90
1050
100
SMC LIGHT & POWER
LA16666
A DIVISION OF ARC-GEN LTD
A DIVISION OF ARC-GEN LTD
12
120
150
LA16666
Figure A SERIAL NO. PLATE
3.2.1 VEHICLE IDENTIFICATION NUMBER
The number is shown on the Serial Number plate and is also stamped into the front
right hand underside of the chassis.
3.3 DECLARATION OF CONFORMITY
The Telelights supplied by SMC Light & Power in conformity with all the applicable
EEC Directives and are furnished with an EC Declaration of Conformity, an example is
shown in Fig. B.

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EC DECLARATION OF CONFORMITY
1. MANUFACTURER
1 SMC Light & Power
A division of Arc-Gen Ltd.
Belchmire Lane, Gosberton,
Lincolnshire
PE11 4HG
United Kingdom
2. EC CONFORMITY CERTIFICATE No.
2 SMC/EC/2248
3. CERTIFICATE HOLDER
3 As above
4. ISSUING DIRECTIVE APPLICABLE
2006/42/EC
2000/14/EC and 2005/88/EC
2004/108/EC
2006/95/EC
5. NOISE TECHNICAL CONSTRUCTION FILE
No. SMC/2010/0255 Date 6/08/10
Measured sound power level 84 dB (LWA)
Guaranteed sound power level 85 dB (LWA)
6.
Conformity assessment procedure to EC
directive 2000/14/EC annexes V1 (UK
regulation SI 2001/1701) unit verification.
Notified body: AV Technology Ltd. AVTech House
Birdhall Lane, Cheadle Heath, Stockport, Cheshire
SK3 0XU
7. DESCRIPTION OF EQUIPMENT
Make: SMC Category: Mobile Lighting Tower/Generator
Model: TL-90 Type of drive: Diesel (Kubota D905)
Serial No.(s)
Manufacturer: SMC Light & Power
A division of Arc-Gen Ltd.
Power/Revs. 7.4 kW/1500 rpm
8. Complies with transposed harmonised standards, national standards and technical specifications
applicable to it. In particular one or more of the following;
EN 292.1, EN 292.2, EN 60204, EN 50081-1, EN 50082-1, EN 349, EN12385-1,2,3.
ISO 1103, ISO 3853, ISO 4223-1, ISO 7641-1, IEC227, IEC972,
BS 7211, BS 6651, BS 7530, BS 5000, BS AU114b, BS AU113c, BS AU50
9.
Signature of responsible person ____________________ Issued on behalf of:
Name of responsible person Robin Brand SMC Light & Power
Gosberton Lincolnshire
PE11 4HG
Position of responsible person Chief Design Engineer United Kingdom
Date ____________________
Figure B

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3.4 TL-90 TECHNICAL INFORMATION
ENGINE
Model
Kubota D905-BG
Type
Diesel Water Cooled
Cylinders
3
Bore mm
72
Stroke mm
73.6
Displacement cu.cm.
898
Power. kWm
7.7
RPM
1500
Oil Sump Capacity. Litres
5.1
Engine Stop System
12v Solenoid. Energised To Run
Fuel Pump
12v Electric
Fuel Tank Capacity. Litres
130
Fuel Consumption. l/hr.
2.25 (at Continuous rating)
Max. Hours Run. 4 Lamps Only
80
Starting Battery. Ah-V
70 12
Alternator Amps-V
30 12
ALTERNATOR
Type
Mecc Alte LT3 110/4P
Voltage
230v
Frequency. Hz
50
Continuous Power. kW
5
Standby Power. kW.
5.6
Voltage Stability
6%
Std. Outlet Sockets
2 x 16 Amp 230v
2 x 16 Amp 110v (Option)
Mast: Max. Height (Metres)
9
Mast: No. of Sections
9
Mast Raise Time secs.
12
Mast Lower Time secs.
18
Lamp Specification
4x 1000w 230v Metal Halide
Total Light Output Initial lumens
106,000 per lamp head
Total Light Output Mean lumens
85,000 per lamp head
Mast Actuation
Hydraulic-185bar 12v Power Pack
Lamp power tilt (optional).
12v
Tyres
175R13
Tyre Pressure bar/psi
2.4/35
Dimensions Transport Mode
2500L x 1320W x 2100H
Dimensions Fully Deployed
2500L x 2630W x 9000H
Weight. Kg. Fully Fuelled
1050
Weight. Kg. No fuel
933
Noise Level @ 7 Metres
60dB(A) Approx.
Sound Power Level LwA
85dB(A)
Vibration m/sec sq.
Less than 2.5
Enclosure Protection.
IP 23
Max. Wind Speed kph (mph)
100 (60)
Bund 120% of fluid content
Engine Liquids & Fuel Tank
* When fitted with Power Tilt option. Standard height 8740mm.

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4. OPERATION
4.1 INSPECTION & PRELIMINARY OPERATION
4.1.1 Prior to each operation of the Telelight, including raising or lowering the mast, a
thorough inspection should be made. Included in this inspection must be:
a) Wire ropes and pulleys. Check rope for fraying, kinks and stretching.
Replace if not good working order.
b) Power cable and fittings. Check for chaffing and cuts and other visible
defects. Replace if not in good working order.
c) Mast hydraulic cylinder. Inspect mountings and check for hydraulic leaks.
d) Mast wear pads. Inspect for damage or wear, replace as necessary.
e) Rotation mechanism functions correctly. Check rollers & bushes for damage
or wear, replace as necessary.
f) Lamp fittings are in good working order.
Important! Do not operate lamps with glass damaged or missing,
replace damaged glass immediately. Failure to do so can damage
health. Faulty lamps must be replaced immediately. Failure of lamp can
also result in damaged to the control gear if unit remains switched on.
c) Outriggers, prop stands & jockey wheel.
d) Check mast deployment warning device is fully functional.
e) Check park brake is operational.
f) Ensure all operation and warning labels are legible.
4.1.2 Check fuel, engine oil, and coolant if appropriate, as per the instructions in the
engine manufacturer’s handbooks.
4.1.3 Check bund daily for fluids, drain into suitable container if necessary.
4.1.4 Each week and before each new operation of the mast; hydraulic cylinder, wire
ropes, electric cable and sockets, lifting points, brakes and all other safety
aspects should be checked by an authorised person. Check battery electrolyte.
4.1.5 Notwithstanding obligations as described in 4.1.1, at 12 monthly intervals a
thorough examination should be made of the Telelight structure, mast, mast
hydraulic cylinder, and lifting points (if applicable). Wire ropes should be
thoroughly examined at 6 monthly intervals. It is recommended that new
ropes are fitted every 12 months. A competent authority should issue new
certificates after satisfactory testing. (See mast maintenance section)
Note! The latter two items apply particularly to the UK. Units used outside the
UK should be homologated to conform to local regulations, the onus being on
the user to research these and comply. In the absence of local regulations
follow as a minimum the rules as above for the UK, and consult your
distributor.

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4.2 MANOEUVRING
4.2.1 Use sufficient persons and equipment to control the lighting tower when
manoeuvring. Never manoeuvre with the mast raised. Prior to raising mast
check for overhead obstructions and in particularly overhead electric power
lines.
Please consult HSE Guidance Note GS 6, Avoidance of danger from
overhead electric power lines. This provides guidance to the user on safe
working practice when working in close proximity to overhead electric power
lines. The information within this publication should be adhered to at all times.
Please note that the Telelight is fitted with an audible warning system which
automatically be activates when the mast is raised or lowered.
The warning system also interacts with the park brake, should the park brake
be released, to inadvertently move the Telelight whilst the mast is deployed, the
audible alarm will sound and the mast will automatically lower. Beware of
mast movement.
WARNING
4.3 MAXIMUM WIND SPEEDS
Never raise the mast or allow it to remain elevated in wind speeds in excess of
100 kph (60mph).
WARNING
4.4 EARTH REQUIREMENTS
Australian Standards do not require the Telelight to be earthed. Should the
Statutory Authority where the Telelight is being operated require the Telelight
to be earthed an external earth connection is situated at the front left hand side
of the machine. A copper cable with a minimum 10mm sq. should be fitted to
this and connected to a suitable land-dispersion facility. The resistance of such
a conducter, including contact resistance, must not exceed 0.15 Ohms.
Earthing should be carried out by an authorised person and in the first instance
must comply with local regulations.
4.5 MINATURE CIRCUIT BREAKERS (MCB’s)
These are incorporated in the control panel to protect both lamp and external
socket outlets, they are switched manually.